rod OPEL 1900 1973 Service Manual

7C. 941973 OPEL SERVICE MANUAL
7. Drive out retaining pin and shaft and remove se-
lector detent. See Figure 7C-93.Figure
7C-93Figure
7C-94 - Exploded View of Selector Lever
8. To replace bowden cable in selector lever, knock
off selector handle, remove screws from clamping
piece and pull knob.
9. Remove pull knob and bowden cable, taking care
not to lose lock bolt bushing, thrust springs, ‘and
washer.
10. Place thrust spring, bushing, washer, and thrust
spring onto new bowden cable, in that order, and
insert cable into selector lever.
1 I. Slide pull onto selector lever and clamping piece
onto cable.
12. Heat up new selector lever handle in water to 176
degrees F. and push onto selector lever.
13. Set dimension between pull knob and selector
lever handle at
.4 inch and tighten set screws.
14. Lubricate selector lever detent and shaft. Install
detent, align selector lever with support, install shaft,
and drive in new retaining pin.
15. Install assembly to support housing and install
intermediate selector lever.
16. Install assembly to vehicle and install neutral
start switch.
17. Install console lights and cigar lighter connec-
tions to console and install console to vehicle.
18. Lubricate and connect selector rod to intermedi-
ate selector lever and adjust according to Figure 7C-
198.
MAJOR REPAIRREMOVAL AND INSTALLATION OF AUTOMATIC
TRANSMISSION
Removal
- Opel 1900 and Manta
I. Disconnect battery.
2. Remove dipstick.
3. Remove screws from fan shroud.
4. Remove 2 upper starter bolts.
5. Raise car and provide support for front and rear
and drain oil.
6. Remove bolts from engine support brackets, both
sides. Let brackets hang by front bolts. See Figure7c-105.
7. Remove flywheel cover pan.
8. Remove exhaust pipe from manifold and unhook
rubber tailpipe suspension.
9. Remove drive shaft. Do not misplace thrust spring
in spline.
10. Disconnect cooler lines at flexible hoses.
II. Detach both stabilizer supports from
crossmem-ber to body supports and loosen stabilizer bolts in
lower control arms. See Figure X-84, Callout “B”,

AUTOMATIC TRANSMISSION 7C- 95
12. Place suitable jack under transmission and
remove transmission support bolts.
13. Lower transmission enough to remove detent
cable and modulator vacuum line.
14. Remove speedometer cable.
15. Remove selector lever.
16. Mark flywheel and converter for reassembly in
same position, and remove converter to flywheel
bolts. See Figure 7C-106.17. Remove converter housing to engine bolts and
tiller tube.
18. Pry transmission loose from engine.
19. Keep rear of transmission lower than front to
prevent converter from falling and install converter
holding fixture J-21366. Lower transmission and
move to bench.
Installation. Opel 1900 and Manta1. Assemble transmission to suitable jack and raise
transmission into position. Rotate converter to per-
mit coupling of fly wheel and converter with original
relationship. Remove J-21366.
2. Install tiller tube and converter housing to engine
block bolts. Torque to 35 lb. ft. DO NOT over
torque.
3. Install flywheel to converter bolts. Torque to 30 lb.
ft.4. Install detent cable to transmission.
5. Connect oil cooler lines.
6. Install lower bolt on starter. Torque to 40 lb. ft.
7. Connect shift linkage to transmission.
8. Connect modulator line.
9. Connect speedometer cable.
10. Install transmission support.
11. Install drive shaft. Torque U-Bolts to 18 lb. ft.
12. Install flywheel cover pan. Torque to 15 lb. ft.
13. Install engine support brackets.
14. Reconnect exhaust system.15. Attach stabilizer supports and tighten stabilizer
bolts in lower control arms.
16. Lower car.
17. Install starter bolts. Torque to 40 lb. ft.
18. Reconnect battery.
19. Fill transmission with fluid as described in
Specifications. Check selector lever and detent cable
adjustment.
Removal GT1. Disconnect battery.
2. Remove dipstick.
3. Pull throttle control rod off ball pin.
4. Remove screws from fan shroud.
5. Raise car and provide support for front and rear.
6. Remove heat protection shield from right side to
make room for exhaust pipe removal.
Figure 7C-957. Detach exhaust pipe from manifold flange.
8. Unhook damper rings on front muffler and tail
pipe from brackets on body floor panel. Place ex-
haust pipe assembly onto rear axle. See Figure 7C-
96.9. Remove propeller shaft. Make sure that spring in
front universal joint does not get lost.

7C- 961973 OPEL SERVICE MANUAL
Figure 7C-96
10. Detach rear engine support from transmission
crossmember. See Figure 7C-97.Figure 7C-98
Figure
7C-9711. Support transmission below oil pan with a suita-
ble jack.
12. Unscrew transmission crossmember from side
members. See Figure
7C-97.13. Lower transmission as far as possible,
14. Drain transmission oil.
15. Detach selector rod from ball pin of the outer
transmission selector lever on right transmission
side. See Figure
7C-98.16. Unscrew oil cooler pipes from transmission cow-
ter holding with a second wrench. Then plug oil
cooler pipes. See Figures 7C-99 and
7C-101.Figure 7C-99
17. Pull modulator line off diaphragm.
18. Unscrew detent cable retainer from transmission,
pull cable out of transmission, and unhook from de-
tent valve. See Figures 7C-102, 7C-103, and 7C-104.

AUTOMATIC TRANSMISSION 7C-101
Figure 7C-1 16
-117Figure
7C-118 GT Models
Figure 7C-1 17 GT Modelsthat one case services both models and is machined
to accept selector lever on either side with the unused
hole being plugged.
1. Remove retaining ring From parking actuator rod
to selector inner lever. See Figure 7C-119.
2. Remove selector inner lever locking nut from se-
lector lever shaft.
3. Remove selector inner lever from selector lever
shaft.4. Remove selector lever shaft spring pin by pulling
upwards with small pliers.Figure
7C-1195. Remove selector lever shaft. See Figure 7C-120.
6. Remove selector lever shaft oil seal and discard.
Removal of Modulator Assembly
This operation can be performed with transmission
in vehicle using tool J-23
100.1. Remove vacuum modulator From transmission
case. See Figure
7C-94. Care should be taken not to
lose the modulator plunger.

AUTOMATIC TRANSMISSION 712-1033. Remove extension housing and gasket. See Figure7C- 124.
Figure 7C-124
4. Remove parking
paw1 actuator rod from transmis-
sion case.
Removal of Speedometer Drive Gear, Governor
Body and Governor Hub
1. Depress speedometer drive gear retaining clip and
remove speedometer drive gear by sliding off output
shaft. See Figure
7C-125.
7c-125Figure 7C-125
2. Remove the four (4) attaching bolts from the gov-
ernor body and remove governor and gasket. See
Figure
7C-126.Figure 7C-126
3. Remove governor hub snap ring from output shaft
using snap ring pliers, such as J-8059. See Figure 7C-
128.Figure 7C-128
4. Slide governor hub off the output shaft
Removal of Converter Housing, Oil Pump, Reverse
and Second Clutch Assembly
1. Turn transmission in holding fixture so that con-
verter housing is facing up.
2. Remove the seven converter housing attaching

7C-1201973 OPEL SERVICE MANUAL
4. Inspect the secondary valve spring for distortion
or breakage.
5. Clean in solvent, air clean, and blow out all oil
passages. Inspect all oil passages, valve bores for
nicks, burrs or varnish in governor body. Replace if
necessary.6. Install roll pin flush to
,010” below the front face.
7. Install primary valve in governor placing the small
portion of the valve in
first. Use liberal amount of
transmission fluid. There is no spring for the primary
valve.
8. Install secondary valve with small spool portion of
valve in
first.9. Install secondary valve spring.
10. Depress secondary valve spring with small screw
driver and install retainer.
Disassembly, Inspection and Reassembly of
Governor Hub1. Inspect the three oil seal rings. See Figure
7C-189.Figure 7C.189
2. Remove governor hub oil screen. Inspect screen
and clean with solvent and air dry. Replace if neces-
sary. See Figure 7C-191.
3. Install oil screen flush to governor hub.
4. Inspect governor hub splines for cracks or chipped
teeth in splines. Replace governor hub if required.Figure 7C-191
Disassembly, Inspection end Reassembly of
Extension Housing1. Inspect extension housing for damage. Replace
housing if necessary.
2. Inspect parking
paw1 and spring for damage. Re-
place if necessary.
3. If lubricant leakage was noted prior to removal ofU-Joint from extension housing, extension housing
rear seal should be replaced.
4. Use screw driver to pry out extension housing seal.
5. Inspect extension housing bushing. If worn, scored
or damaged, bushing can be removed with remover
and installer tool J-21424-9 used with driver handle
J- 8092. See Figure
7C-192.6. Clean extension housing of dirt and foreign mat-
ter. Install new extension housing bushing using
remover/installer tool J-21424-9 with driver handle
J- 8092. Bushing must be installed flush to shoulder
of exi:ension housing. See Figure 7C-192.
7. Install new extension housing seal using installer
tool
Jo-21426. See Figure 7C-193.
Disassembly, Inspection and Reassembly of Servo
Piston1. Remove servo piston apply rod
2. Holding servo piston sleeve at flat portion of sleeve
with wrench, loosen the adjusting bolt lock nut and
remove. See Figure
7C-194.

7C-1221973 OPEL SERVICE MANUAL
1. SERVO PISTON RETURN SPRING
7. SERVO PISTON
2. SERVO PISTON APPLY ROD
8. SERVO PISTON RETAINING RING
3. SERVO PISTON ADJUSTING SLEEVE9. SERVO PISTON ADJUSTING BOLT
4. SERVO PISTON CUSHION SPRING SEAT 10. SERVO PISTON ADJUSTING BOLT NUT
5. SERVO PISTON CUSHION SPRING
11. SERVO PISTON RETAINER
6.SERVO PISTON RING7D195Figure
7C-195 Servo Piston - Exploded View
Figure
7C-196Figure 7C.198

AUTOMATIC TRANSMISSION 7C-1251. CASE VENT4.3RD CLUTCH7.SUCTION
2. CONVERTER OUT5MODULATOR8.LINE/3.2ND CLUTCH
6. BOOST9.REVERSEFigure 7C-202 Case Front View Oil Passage
Identification
7.
!nspect reaction sun gear drum bushing sleeve
inside case at rear for scoring. If necessary, replace
sleeve before installing rear case bushing.
8. Remove sleeve by grinding. Care must be used in
order that aluminum case is not damaged when
grinding sleeve.
9. Install new sleeve using installer tool J-23130-7
and driver handle J-8092.
10. Install new case bushing using remover and in-
staller tool J-23130-3 and driver handle J-8092.
Bushing should be installed flush with case at rear.
See Figure
7C-203.Figure 7C-2031. Drain Converter. If clutch disc material or
foreign matter has been found while draining con-
verter,
replace entire converter assembly as it can not be
cleaned properly.
2. Air check converter for leaks using converter
checking tool J-21369. Install tool and tighten. Ap-
ply 80 psi air pressure to tool. See Figure
7C-204.Figure 7C-204
3. Submerge in water and check for leaks.
4. Check converter hub surfaces for scoring or wear.
Installation of Selector Lever and Shaft1. Install new selector lever shaft oil seal in case.
Insert selector lever shaft through case from outside.
Care should be exercised so that oil seal is not da-
maged. See Figure
7C-206.2. Insert spring pin in case to secure selector lever
shaft.3. Guide selector lever over shaft and secure with
lock nut.
4. Insert parking
paw1 actuator rod from front of the
case and through hole in case at rear. See Figure 7C-
207.5. Install parking
paw1 actuator rod retaining ring.
Installation of Low Band1. Turn transmission case so that front of case is
upward.

AUTOMATIC TRANSMISSION 7C-1314. Bolt extension housing to rear of case. Torque to
20-30 Ibs. ft. See Figure
7C-221.
Figure 7C-22
1
Installation of Speedometer Driven Gear1. Install speedometer driven gear and housing into
extension housing. See Figure
7C-222.Figure 7C-222
2. Install speedometer driven gear housing retainer
into slot provided in speedometer driven gear hous-
ing. Bolt retainer to extension housing. Torque to
6-Slbs. ft. See Figure
7C-223.
installation of Detent Valve, Modulator Valve,
Modulator Assembly1. inspect detent valve sleeve oil seal and replace if
necessary.Figure 7C-223
2. Install detent valve, sleeve, spring, and spring seat
into case bore using liberal amount of transmission
fluid.
3. Depress detent valve spring and insert spring pin
to secure detent valve assembly. Detent valve sleeve
must be installed with slots facing oil pan. Care
should be taken so that spring pin is inserted into the
groove provided in sleeve and not into one of the oil
passage slots in the sleeve.
4. Install modulator valve and sleeve into case with
small end of modulator valve first.
5. Using new modulator assembly gasket, install
plunger and thread modulator into case and tighten
to
12-15 Ibs. ft. using tool J-23100. See Figure 7C-
224.
Installation and Adjustment of ServoAdjustment of servo can be performed with trans-
mission in vehicle.
1. Install servo apply rod, spring and piston into case,
using liberal amount of transmission fluid.
2. Compress servo piston spring using compressor
tool J-23075, lightly tapping servo piston while com-
pressing until piston is seated to avoid damage to the
oil seal ring.
3. Install servo retaining ring. See Figure
7C-225.Remove compressor tool J-23075.

7C-1321973 OPEL SERVICE MANUAL
Figure 7C-226
Figure 7C.224
Figure 7C-225
4. Using 3/16” hex head wrench on servo adjusting
bolt, adjust servo apply rod by tightening adjusting
bolt to 40 lbs. in. Back off bolt five (5) turns. exact/u.See Figure
7C-226.5. Tighten lock nut holding adjusting bolt and sleeve
firm with hex head wrench. See Figure
7C-227.
installation of Valve Body
1. I&all steel balls in oil passages in case. See Figure
7C-228.Figure 7C-227
2. Install new case to transfer plate gasket.
3. Locate guide pins in transmission case for correct
alignment of valve body and transfer plate. See Fig-
ure
7C-229.4. Install manual valve into valve body bore using
liberal amount of transmission fluid.
5. Install long side of manual valve link pin into
manual valve. See Figure
7C-230.